Speed Control Methods

for Stepper Motors

Stephen Sutara

Application Note

Team 6

ECE 480 Spring Semester 2009

Executive Summary

Stepper motors take in electrical signals and output mechanical movement. Their high

accuracy and low cost make them popular in applications ranging from printers to

cameras. Current in the stator coil creates magnetic fields that move a rotor. As the

current into the stator is modified the rotor spins at different speeds. There are three main

methods to accomplish this feat: series resistance, gearboxes and voltage regulation. The

series resistance method incorporates a resistor in series with the motor. Different values

of resistance will change the current through the circuit, thereby altering the motor speed.

A second method of speed control comes through mechanical gears. A gearbox utilizes

gear ratios to step down and up rotational speed and torque. A set of known equations can

allow a designer to select gears with a certain number of teeth to achieve the proper

speed. A third method for stepper motor speed control is voltage regulation. By utilizing

an LM555 timer, the current supplied will become a square wave. The “high” time of the

signal will be when the rotor rotates.

These three methods allow for the speed to be controlled in any number of applications.

Their ease of construction allows for quick speed control solutions. In cases with more

complex needs, one single solution may not be enough. The three solutions presented

may be integrated together as needed.

Key Terms: Stator, Rotor, Potentiometer, Pinion, Gearboxes

1. Introduction to Stepper Motors

Stepper motors are brushless, synchronous electromechanical devices that translate

electrical pulses into mechanical movement (Stepper Motor Basics). A stator and rotor

utilize magnetic fields to rotate. As seen from Figure 1 below, the stator has current-

carrying coils.

Figure I: Stator and Rotor Picture

A single coil carries current at one time, causing the magnetic rotor to align itself with the

generated magnetic field. Each coil is turned on and off in response to the pulse supplied

to stepper motor. The pulse frequency determines the speed of rotor rotation. The number

of teeth determines the angle of rotation. As the number of teeth increases, so does the

rotor accuracy. This design results in an open loop system, so a complicated feedback

loop is unnecessary (Stepper Motors). This fact combined with their relativly low cost

and small size make stepper motors an ideal solution in applications with velocity,

displacement or directional concerns. Real-world applications include printers, CD-

ROM’s and the zoom feature on cameras.

2. Application Note Objective

The speed of the rotors rotation in a stepper motor may be controlled in a variety of ways.

Three such possibilities are through a series resistance, gearbox and voltage regulation.

Each type has advantages over each other, and a methods implementation depends on the

motor application and functionality.

3. Speed Control Methods

3.1 Series Resistance

Stepper motors operate based on input. As seen in Figure II below, speed and current are

directly proportional to each other.

Figure II: Sample Current vs Speed Plot

By placing a resistor in series with the motor as in Figure III, the supplied current limited.

V=I*R explains this outcome.

 Figure III: Series Resistance Layout

Potentiometers allow for the most flexibility in this setup. In cases where the load will

require different torques, the demanded current varies thus the resistance must be

flexible.

Because stepper motors vary a great deal in capabilities, a single circuit will not suffice.

For the purposes of this paper, a general case is considered. Considerations for this

method include the range of current. The resistor or potentiometer must be able to limit

the current. Often times the current levels are larger then most normal components are

meant to handle. The selected part must have high current tolerances as a result.

3.2 Gearboxes

Mechanical gears provide another solution for speed regulation. This method requires a

stepper motor to connect through an intermediate gearbox. The properties of gear ratios

allow for this method. Gear Ratio= Output gear # teeth / Input gear # teeth. The output

speed is given by the equation Output Speed = (Input Speed)/(Gear Ration). It is

important to understand gear ratios because it affects torque, as well. Motor Torque x

gear ratio = torque at the wheel (Boston Gear Catalog). The chart below provides simple

examples.

Figure IV: Gear Ration Example

The chart may be summarized by saying if a smaller gear is driving a larger one, the

larger gear will output more torque but move slower. In the alternative case, a larger gear

driving a smaller one will result in a faster spinning, but less torque output.

3.3 Voltage Regulation

The final method for stepper motor speed control is through voltage regulation. Many

chips exist to achieve this, but the one discussed is the LM 555 Timer. The layout for

Astable Operation may be seen below:

 Figure V: LM555 Astable Layout

By selecting the proper values for RA, RB and C, the output can be manipulated into a

square wave. The “high” time is given through the equation Thigh = 0.693(RA + RB)C and

“low” time is given by Tlow = 0.693(RB)C. The Duty Cycle is thus given through the

equation D = (RA + RB)/ (RA + 2RB). Another important piece of information is the

frequency. It is given by 1/( Thigh+ Tlow) or 1.44/( (RA+ RB)C). With this information, the

speed can be regulated as needed (DC Speed Control).

4. Conclusion

The simple construction of stepper motors makes them ideal for applications where

precise movement is required. They are easily integrable into systems and made to meet

specifications. The methods of series resistance, gearboxes and voltage regulation are

generic. They may be broken down into electrical and mechanical categories, which

provide the advantage of two methods toward a solution. They may also be mixed and

varied. For instance, the resistors utilized in the LM555 timer could be potentiometers to

allow for a wide range of speeds.

 References

"Boston Gear Catalog." Boston Gear 2009. 29 Feb. 2009 <http://www.bostongear.com>.

"DC Speed Control." DIY Electronics (2002): 1-3. 1 Mar. 2009

<http://www.kitsrus.com/kits.html>.

Stepper Motor Basics. Solar Robotics. Industrial Projects. 29 Mar. 2009

<solarbotics.net>.

"Stepper Motors." Electronics Information Online 20 Feb. 2007.